Manufacture of staple fiber



March 4', 1941.

4 Sheets-She e't 1 Filed May 25, 1957 Snmmtors YDEN B. KLINE LAVERN J.JORDAN N M -WH m N m Nb m w Q Q m N, .l NN NN fix mm QM. F C r o o I: 2 o 1 m m w m N Nu m. mm .m m m m N N) ELL attorney March 4, 1941.

H. B. KLINE ETAL MANUFACTURE OF STAPLE FIBER Filed May 25, 1937 h I r 4 Sheets-Sheet 2 Snnentors HAYDEN B.- KLINE LAVERN u. JORDAN attorney March 4, 1941.

H. B KLINE ETAL MANUFACTURE OF STAPLE FIBER Filed Hayes, 1937 4 she ets sheet s Snventots E mm LR w 8.... N R WE w L attorney March 4, 1941. KLINE ETAL 2,233,411

' MANUFACTURE OF STAPLE FIBER Filed May 25 1937 4 Sheets-Sheet 4 Fin. 3|.

Fin. 5.

ZShneutorc HAYDENB. KLINE LAVERN J. JORDAN ttomeg i .7. Firs. B.

Patented Mar. 4, 1941 'Fairyiew-Village, Ohio, assignors to Industrial Rayon Corporation, Cleveland, Ohio, a corpora- 1 tion of Delaware.

1' Application May 25, 1931, Serial No. 144,582

' 9Claims. (01. 18-8),

This invention relates to'the manufacture for textile purposes of filament aggregates characterized by the presence of substantially parallel fibers of staple length; for example, staple fiber chips. Q

Fabrics formed of yarn that has been spun, as in. the manner of cotton or wool, from staple fiber have grown in popularity because of their desirable characteristics, unobtainable in other types of fabrics. For instance, such fabrics have a more attractive appearance, the luster being in general more subdued than that of fabrics formed of continuous artificial silk filaments. Such fabrics, furthermore, have aninherent softness which has been found desirable in the textile arts. In consequence ofsuch characteristics, the demand for staple fiber has increased to such an extent that, whereas until comparatively recently waste derived from the manufacture of continuous artificial silkfthread constituted almost the entire source of staple fiber, 'at the present time it furnishes only a'very smallfportion of the total supply I f In the manufactureof spun yarn from waste,

the waste is severed into short lengths which,

prior to and while beingf'spuninto yarn, are treated similarly to fibers of cotton or wool. The waste itself is often'of low tensile strength and/or of non-uniform filament *size, in addition. to which the severing operation usually results in undesirably wide variations in thele'ngths of the fibers. Moreover, since such wasteis usually badly tangled, drastic" opening; carding, gilling,

combing and like operations are necessary to prepare the fibers for spinning. which operations result in serious injury 'to and cause further variations in tne lengths ofthefibers. Thus yarn produced from waste is; notusually of as high a quality as isjordinarily desired For these reasons, most of the staple fiber now employed in the textile industry does notfioriginate as waste, but is produced as'staple fiber ac-'- cording to one of two general methods.

According to one of said methods, continuous artificial silk threads collected in the conventional manner in the form of .a package are severed into fibers of staple length, such severing being accomplished in the case of viscose artificial silk threads 'bycutting the threads while in the acid condition; i.e., while they still contain the coagulating bath liquid. The fibers thus formed are subjected to the necessary processing treatments, usually by immersing the fibers in vats containing the desired "processing liquids. In the case of fibers formed of viscose artificial silk threads, the fibers may-be immersed insequence in vats containing respectively a washing liquid, a desulphurizing liquid, a second washing liquid, etc. -The fibers are freed of moisture by being passed through a suitable drying machine.

This method of manufacturing staple fiber is disadvantageous in several respects. Because the fibers are intermixed when subjected to the processing treatments, they tend to felt together. After the fibers have been dried, they are-in a, mass in which the fibers are disposed in all directions and are in fact considerably tangled. Therefore when the staple fiber is spun into yarn, it is necessary to subject it to un-,

usuallydrasticopening,carding,gilling and combing operations. These operations, which naturally add to the cost of the resulting yarn,

usually involve a considerable waste of fibers, generally 10% or more, as well as impairment of the quality of the product.

Moreoventhis method of manufacturing staple fiber requires considerable time and labor, since it is necessary to subject the masses of fiber to the treating liquids for relatively long periods of time during which the several operations must,

be closely tended in order to insure thorough processing and since the steps of transferring the fibers from bath to bath entail a good deal of time and labor. Furthermore, considerable manufacturing equipment, and consequently con-, siderable plant space, is required to produce, staple fiber by this-method. All such factors add to the cost of the staple fiber and therefcreto the cost of the yarn spun therefrom.

In the other generally employed method of manufacturing staple fiber, continuousartificial silk thread is first formed in the ordinary ;man-,

ner by extrusion of a suitable solution ,into a A large number ofsuchi 35 liquid coagulant. threads are gathered into a thick bundle which is usually, but need not necessarily be, collected; in package form. In either case,the bundle is subjected to the desired processing, treatments,

for example, as :washing, desulphurizing, re-

washing, etc. When the bundle hasbeensufiia ciently processed, it is'dried, after. .which it issevered by a cutting operation into fibers,.-of;;i

staple length.

It is the practice in large as possible, even as high asYlOOflQQ denier.

lengths of the fibers, probably scar part to other. When such staple fib ment, the fibers, because tion, dispose themselves that when later the fibers, arelunbaledathey must;

be subjected to what' w necessarily drastic, open combing operations,- .wit

1d w ssrbeu this proce ssf in 1156 reduce handling costs, to make the bundles as lami a-ra ning. and a the previously; indicated disadvantages .of}.waste,: impairment of.1

quality, and added cost.

ble periods of time, as a result of which the speed.

of production is necessarily low. Moreover, because of the space requirements of the necessary apparatus and because of the time required to process the bundles on such apparatus, considerable plant space is required. All of these factors add to the cost of production of staple fiber according to this method and to the cost of the yarn spun from such staple fiber.

The above indicated difliculties and disadvantages inherent in the products and processes of methods heretofore commercially used in manufacturing staple fiber are obviated by the present invention. Among other things, the invention provides staple fiber definitely' superior quality in a new and advantageous form, as well as a novel, highly advantageous commercial apparatus and process for manufacturing staple fiber. While the invention in its broad aspects is applicable to the manufacture of staple fiber, inter subsequently severed, as

alia, from casein, viscose, cuprammonium cellulose solution, cellulose acetate and the like, it may be employed to particular advantage in and will be described hereinafter as applied to the manufacture of viscose staple fiber. o

-In the preferred method of practicing the present invention, according to which staple fiber is produced by a mechanized continuous process, a plurality of separate groups of small threads are formed in the conventional manner by extrusion of viscose into a suitable coagulating medium, each of said small threads preferably comprising a large number of filaments. The several small threads of each group are preferably combined into a large thread which is continuously treated in a compact space, preferably in a large number of closely spaced generally helical turns, by means of a series of suitable thread-storage devices. The large threads passing from several of said series of thread-storage devices may thereafter be combined into a bundle which is by a cutting operation, into fibers of staple length. The features-of the invention will be explained in'detail in the following discussion when read in connection with the accompanying drawings,

wherein Figure 1 is a side elevation of a machine comprehended by the invention; Figure 2 is a a side elevation on an enlarged scale showing in greater detail the lefthand end of the apparatus shown in Figure 1, parts being broken away; Figure 4 is a side elevation on the same scale as Figure 3 showing in greater detail the right-hand end of the apparatus 'shown in Figure 1, parts being broken away; Figure 5 is a. sectional elevation, on the same scale as Figures 3 and 4, along line 5-5 of Figure 2; Figure 6 is a sectional ele'va'.tlon, on the same scale as Figures 3 and 4, along line' 66 of Figure 1, parts being omitted for the sake of vantage in Figures 1 clearness; Figure 7 shows the form of staple fiber of the present invention before it is dried; and

Figure 8.shows the form of staple fiber of the present invention after it is dried.

The illustrated machine, as shown to adfaces extending lengthwise of the machine each of which comprises a plurality of superposed guide l2,into a. bundle C.

and 2, has two operating the bundle C is preferably combined by suitable processing units, three such processing units being shown in the illustrated embodiment. As shown in said figures and to better advantage in Figures 3 and 4, each of said units comprises a trough l containing a coagulating bath in which is disposed a group of spinnerets 2. The various small threads A formed by the spinnerets of each group are combined by suitable means, as a suitable guide 3, into a large thread B which passes in sequence to each of a horizontal series of threadstorage devices bymeans of each of which devices a relatively long length of thread is stored while being subjected to processing treatment.

Each of said thread-storage devices may take the form of a thread-storage, thread-advancing reel which is adapted, during rotation thereof,

application of Hayden B. Kline and Louis S.

Fryer, Serial No. 7,115, both filed on February 18,. 1935.

Each of such reels, as, shown and described in detail in said applications, comprises two generally cylindrical sets of interdigitating bar members, the sets being rotatably mounted, from one end only of the reel, about axes which are slightly offset from and inclined to each other. One set of bar members is rotatedby the other set, which may be positively driven. Because of the relation of the axes of the sets and the interdigitating relation of the bar members of the sets, as the two sets of bar members rotate about their own axes the thread is caused to wind on the reel and be advanced longitudinally thereof in a plurality of spaced, generally helical turns. I In the present invention, the turns of thread are advanced from the, supported'end of the reel to the free end thereof. Generally speaking, the reels of said ap plications operate in the manner described in Knebusch application Serial No. 652,089, filed.

January 16, 1933, for Winding reel.

Any suitable number of such thread-storage, thread-advancing reels may be employed ineach series, depending upon the number of processing treatments to which the thread is to be subjected. It is in general desirable to perform only one the copending.

processing treatment on a single reel, this in view of difliculties resulting from intermixing of the processing media. Identical processing treatments are applied to the large threads B on corresponding reels of the several series. In the illustrated embodiment of the invention, each horizontal series comprises seven reels bearing reference numerals 4 to ID, inclusive, except that on each side of the apparatus one of said series is provided with an additional reel I I which serves all of the series of reels on the same side of the apparatus.

Before passing to reel H, the several large threads B produced on the same side of the apparatus are combined by suitable means, such as After leaving reel H,

means, such as guide I, with a like bundle formed wet into fibers of staple length. The wet staple fiber so produced may be discharged into or onto a drying'device l6 of suitable construction, by means of which the staple fiber may be dried continuously with its production. I

In the .illustrated embodiment of the inventiongthe several series of reels are horizontally disposed, the reels in all series on the same side of the machine being positioned with their free ends extending in the same direction.- All of said reels are adapted during rotation thereof to advance the threadin a number of generally helical turns toward the free end thereof. The illustrated embodiment of the invention shows the preferred relationship of the reels in eachseries with respect to each other; that is, the reels are disposed in offset relationship with the supported or receiving end of each reel other than the first in apposite relation tothe. unsupported or discharge end of the preceding reel in the series- If desired, other types of reels or other arrange ments of reels may be employed.

The illustrated arrangement of reels possesses numerous advantages, among them convenience in transferring the thread. Indeed, such an arrangement is exceedingly advantageous when reels, of the type contemplated are employed, since such reels are self-threading in the sense that when the thread is contacted with the reel or, at the most, wound once or twice about the reel, the thread is caused to wind on the reel and be advanced lengthwise thereof in a plurality of closely spaced, generally helical turns. The reel threads itself up and when completely threaded up discharges the thread from the unsupported end thereof without becoming entangled in the apparatus. Therefore, the operator need only start the thread on a given reel and leave it to work thereafter. at some other part of the machine. y,

Other advantages are provided by the arrangement of the reels in the aforesaid offset relationship with the supported end of each reel other than the first in apposite relation to the unsup-- ported end of its predecessor. When the reels are so arranged, the thread may pass directly from each preceding reel to its successor without the necessity of materially changing its direction, as would be the case if the reels had their free ends extending in the same direction but were not disposed in offset relationship. It is well known that freshly formed thread is extremely weak; so that if it were necessary to mate'rially change the direction of the thread in passing between reels, as by the interposition of direction-changing guides, excessive stresses might easily be imparted to the thread.

It is also well known that the angle thread guides between the reels, the fact that the angle is limited would necessitate a considerably greater spacing of the reels than is required when the reels are disposed with their discharge and receiving ends in apposite relation; Therefore, the illustrated offset arrangement of reels makes possible a machine of considerably reduced len th as compared with that which would otherwise be required.

While thereels may be supported and driven in various 'ways, in the apparatus shown in Fi ures 5 andrlieach of the reels is supported by means of a bracket" ll carried by a gear box l8. As shown, a'plurality of fsuch gear boxes may be provided lengthwise of the 'machine, each gear boxfsuppo'rting a limited'number of reels on its opposite sides. "'fTh'egear'boxes l8' are supported by the frame structure of the machine,which is comprised of upright members I9 between the ends" of adjacent 'gear boxes, longitudinally extending membersZll belovthe gear boxes, and cross members 2!; f At. the end. of the illustrated machine at which the" threads are formed, the

frame structure of the machine is widened and provided with members 22 to support the superposed spinning troughs; I, as shown in Figures 1,2and3.

In the illustrated embodiment of the invention,'the reels in each series are rotated by a driveshaft 23 extending longitudinally of the machine through all gear boxes I8. For driving the reels inthe corresponding series on opposite sides of the machine; two such shafts 23 are contained in each gearbox. The reels are driven from said shafts by means of suitable gears 24 and 25. The shafts of eachpair of reels journalled in the gear boxes are rotated in opposite directions by means of intermeshinggears 26 and 21 mounted on said shafts. As shown in Figure 6, corresponding shafts 23 in the superposed gear boxes may be connected in driving, relation by means of chains 28, one of the lowermost of such shafts 23 being driven froma suitable source of power, such as motor 3|.

, In the embodiment shown, a suitable change speed device 32 is provided between the motor and shaft 23, said device being connected by chain 33 to the motor and by chains 34 to said shaft '23. By means of change speed device 32, the speed of rotation of the reels may be adjusted as desired independently of that of the driving means for the spinning pumps and independently of that of cutting device IS. The reels may be andpreferably are all rotated at the same peripheral speed; however, if desired, certain reels in each series; maybe rotated in increasing pe-' ripheral speeds so as to stretch the thread or at decreasing peripheral speeds to provide for shrinkage of the thread. If desired, certain reels need not be positively rotated, but may be rotated by the thread being drawn off the reel by'a succeeding.device. As shown in Figures 1, 2 and 4, ahousing 35 may be provided to enclose motor 3| and change speed device 32, said housing being omittedin Figure 6 for the sake of clearness. Suitable processing treatments may be applied to'the thread while stored on the various reels.

Thus it has been found desirable to employ each first reel. 4 as aholding reel, on which the thread passing from the coagulating bath contained in the corresponding trough I is stored to allow coagulation of the thread to proceed to substantial completion. Although a suitable coagulating liquid may, if desired, be applied to the thread stored on such reel, it has been found that no suchliquid need be applied to the thread on this reel, the liquid carried by the thread from the coagulating bath having been found sufiicient for this purpose. In the illustrated embodiment-{of the-invention, the latter procedure is followed,-the liquid dripping from' each reel 4 being returned tothe corresponding coagulating bath by means of the tray 36 extending back to trough I.

In each series of reels, the thread may to advantage be subjected to a suitable treating liquid to regenerate the cellulose content of the thread while it is stored on the reel 5, after which the thread may be subjected to washing liquid on.

reel 6, desulphurizing liquid on reel I, washing liquid on reel 8, bleaching liquid on reel 9, washing liquid on reel 10, and a soaping or oiling liquid on reel ll. Of course, the above treatments may be varied and the number and kind of I 31 is positioned above each reel from which distributor the processing liquid is showered onto the thread on the reel. As shown in Figures 1, 2, 3 and 5, the reagent distributors for corresponding reels in corresponding series on opposit sides of the machine are connected to a pipe 38, .which communicates with a supply pipe 39,

extending longitudinally of the machine. A collecting trough 40 of suitable design is positioned below each reel.

The supply system illustrated in Figures 1, 2 and 3 comprises a header box 4| to which the liquid is supplied from a suitable source, such as storage tank, from a pipe 42. A discharge pipe 43 is associated with each header box, the inlet orifice of the pipe being positioned at the proper level to maintain the desired head of liquid in the box. The corresponding reagent distributor sup-. ply pipe 39 communicates with the header box at the bottom thereof. In operation, the processing liquid is supplied through pipe 42, and passes through corresponding pipe 39, the excess passing out through discharge pipe 43, from which it returns to the source of supply for pipe 42.

'In the illustrated embodiment of the invention,

\ the header boxes for the machine are disposed at one end thereof, thereby making possible a high degree of simplification in the construction of the machine, as well as in the arrangement of the piping. In said embodiment, a bank of header boxes is provided for the reagent distributing systems for each two corresponding. horizontal series of reels on opposite sides of the machine. The various banks of header boxes for the superposed series of reels are superposed, being disposed between the coagulating baths. They are supported in any suitable manner by the frame of the machine.

Each of the illustrated collecting troughs 46 comprises a bottom, sides and back, through which latter the'driving and supporting means for the reel project. Ledges 45 may be provided at the front edges of the sides and bottom to retain the liquid. As is apparent, the trough as a whole is of a design which permits ready accessibility to the reel for operating purposes and which prevents splashing and scattering of the processing liquid applied to the reels, thereby conserving the processing liquid and protecting the operator. While the troughs may be supported by any-suitable means, in the illustrated embodiment of the invention each is supported by arms 46 and 4'! fixed to the longitudinally extending members 26 of the frame of the machine. Suitable means may be provided to remove the liquid collected" in each trough. As shown, each of the illustrated troughs is provided with a drain pipe 48, the drain pipes 48 for corresponding superposed troughs communicating with a conduit 49 which in turn is connected to a maindrain conduit 5|. Each of the main'conduit pipes 5|, which thus conveys a single processing liquid, may communicate with the sewer if the liquid carried by said conduit is one which it is desired not to re-use. If desired, said conduit 5| may, in combination with suitable recirculating and makeup means, communicate with the processing liquid supply means for the corresponding reels, particularly if it is desired to re-use the liquid.

It has been found desirable to provide suitable means between adjacent reels of the horizontally I extending series for the purpose of preventing carry-over by the thread of the processing liquid applied on a preceding reel. In the illustrated embodiment, guides 52 are provided for this purpose. Each guide 52' is shown as disposed within the outer limits of the trough surrounding the reel which the thread leaves, this being for the purpose of allowing the liquid removed from the thread to fall back into the trough. By such means, the amount of liquid carried over from one reel to the succeeding reel is considerably reduced and contamination of the diiferent processing liquids is thereby largely, if not completely,

prevented.

The means for severing the filaments going to make up the consolidated bundle D may take the form of a device similar to that shown in.Figures- 1, 2 and 4. Thus it may comprise suitable rollers 54 and 55 for drawing the consolidated bundle D from the reels and feeding it to the rotating cutter 56, at least one of the rollers 54 and 55 and cutter 56 being rotated by some suitable means. The cutter 56 is provided with knives 51 between which knives and stationary blade 58 consolidated bundle D is cut into fibers of staple length which are discharged from the device through chute 59.

In the illustrated embodiment of the invention, the lower roller 55 is positively rotated through chain 60, change speed mechanism 6|, and chain 62 from motor 63. Cutter 56 is positively rotated through chain 64, change speed mechanism 65, and chain 66 from motor 61. It is desirable to provide means to change the speeds of rotation of the drawing. rollers and cutter to make possible changes in the speeds at which the consolidated bundle D is cut and, what is more important, to make it possible to cut the consolidated bundle D into staple fiber of whatever length may be desired. This may be accomplished by changing the relation between the speed of rotation of the drawing roller and the speed of rotation of cutter 56. If desired, and as shown in Figured, a ro- I tatable roller 69, preferably grooved, may be provided to aid in guiding the bundle of filaments to the cutter. Furthermore, an air jet may be provided, as from. a tube II, to aid in directing the bundle into the cutting blades and to make sure that the cut fibers drop into discharge chute 59.

If desired, the bundles C may be cut separately rather than in the form of a consolidated bundle.

Besides drawing the'bundle C from the reels and feeding the consolidated bundle D to the cutter, the rollers 54 and 55 perform the additional functions of expressing excess moisture from consolidated bundle D and compressing it into a flat, ribbon-like mass. In general, it is desirable to compress the bundle sufiiciently to remove therefrom a considerable amount ofthe liquid contained therein, thus reducing the amount of moisture whichmust be removed from the fibers during the drying operation. However, it is also desirable that the moisture remaining in the bundle have sufficient tension to aid the filaments in cohering. In the illustrated l0 embodiment of the invention, the pressure-between the rollers 54 and 55 may be adjusted by means of screws 12. Because of the pressure put upon bundle D and the surface tension of the moisture therein contained, the product resulting from the cutting of such bundle takes the form of fiat, ribbon-like masses made up of a large number of parallel, coherent fibers of extremely uniform staple length which may be termed Figure '7 shows one of. said chips while still moist. The individual. fibers makingup said chips do not tend to separate, for which reason the chips may readily be handled in moist form without disintegration; in fact, the chip formmay easily be maintainedthroughout the drying operation. The dried chips, of which that shown in Figure 8 is illustrative, are substantially fiat, the

component fibers being coherent, substantially parallel, highly crinkled, and all of highly uniform length. In Figures 7, and 8, the thickness of the fibers is, of course, much exaggerated.

In the illustrated embodiment, the moist chips are discharged from the chute 59 of the cutting device onto the belt 13 of a suitable continuous belt-type dryer which may be of any one of a number of commercial forms. Because of the fact that the moist chips do not disintegrate upon handling, they may, if desired, be collected after,

leaving the cutting deviceanddried at some m other point. The fibers are not in any manner restrained from shrinking while drying, wherefore the fibers may completely shrink during the drying operation and take the crinkled form which, as later explained, is extremely advantageous. As will be hereinafter pointed out, numerous noteworthy advantages over prior practices are provided by the present invention.

In the manufacture of staple fiber, it'ha's long been recognized that,'t0 obtain efiicient production, it is desirable to form as large a bundle as possible. A factor which makes this desideratum difficult of attainment is the fact that, if it is attempted to form a bundle containing a very large number of filaments by extrustion of a spinning solution such as viscose from a single spinneret, the innermost filaments are often incompletely coagulated. Other difficulties arise from the fact that the holes of such spinneret, of which there must necessarily be a very large num- 00 her, readily become clogged.

The present invention overcomes such difficulties by forming a plurality of threads each made up of a great many more filaments than in ordinary artificial silk thread but nevertheless not 65 enough to cause the above-mentioned difiiculties. Such threads are subsequently combined into a, larger thread which may readily be processed. It has been found that, in general, satisfactory results are obtained when the size of the thread 70 formed by each spinneret is under 5,000 denier,

such thread comprising; individual filaments which may be fromrone and one-half denier to five denier in size, V Y

Furthermore, in prior methods of manufacture,

75 in whlchphavebeen formed large bundles ofgfllathe processing fluids. Such difiiculties a ments, processing difliculties havebeenfl x enced as a result of insufiiclent' penetra obviated by the present invention: Since; length of materialmay be stored ina smal pact space, sufficient tim'eis provided p it thoroughly even-thoughthe'thread or und'le may be of very substantialthickness andjm ay contain several thousand filaments. Sufiicie'rit time for thorough processing of the filament's 'may readily be obtained even though the speedof 'prdduction is considerably higher than that' -possible according to conventional methods; Additional advantages along this line result from the fact that; the threads or bundles, when stored on the reels, tend to flatten outintoaa ribbon-like form, in which all of, the filaments are substantially parallel and in which ;n0.itW,ist ing of the filaments occurs. The thicknesspf-zthe thread or bundle is thus .considerablyyreduced.*

Therefore the processing medium; can readily reach all filaments and thoroughly. process-them with much less difliculty and in less time-than would otherwise be the case. Moreoven fleach, thread or bundle is muchmore uniformly; essed than heretofore possible. It has been ascertained,furthermoret size of the thread or bundle which may. be fiiciently processed on a reel may be increasedwith the diameter of the reel. "1r, rorexam ehe reels of the illustrated apparatus areia inches in diameter, threads of filaments,of a 5,000 denier may be rapidly and thoroughly p cessed. Thereforegreels employed in the paratus of the present invention may toj'adva 1- t-age be considerably larger than those whic may be employed in the processing of' artifici f thread. Accordingly, by properly proportioninfg the reels, the threads or bundles may be processed with a maximum of efliciency. It has been found, in general, highly satisfactory results may be obtained if the bundle'of filaments'severed according to the teachings" of the present invention is not much greater than about 50,000 denier, the individual filamentsbe- {45 ing preferably between one and one-half to five denier. The bundle of filaments may be-l ger under certain conditions, depending'largely "seen the size of the filaments. If the bundle of filaments is too large, the staple fiber chips result- 50 ing from the cutting of the bundle will not be sufficiently coherent to hold together andprovide the hereinafter discussed advantages resulting from the preservation of the separate identities of the individual masses of fiber.

High quality staple fiber may be produced ccording to the teachings of this invention at a much greater speed of production than that at which staple fiber may be manufactured according to any of the methods heretofore used. Furthermore, the labor costs required for producing staple fiber according tothe present invention are considerably lower than those required to produce staple fiber according to any of the prior methods. Such high speeds of production and savings in labor costs are made possible as aresult of the mechanized continuous process by which the staple fiber may be produced according to the present invention, in which thick threads are continuously processed and inwhich little or no handling is required, in contradistinction to prior conventional practices.

In consequence of the mechaniz d contin us process by which staple fiber may be produced athighspeed according tothe present invenapparatus of the invention, a. large commercial production of staple fiber may readily be obtained. The apparatus required therefor occupies relatively little space as compared with the space necessary'for the commercial production of staple fiber according to the practices heretofore employed. Therefore considerable savings in plant space and, consequently, in cost of plant construction are made possible by the present invention.

, For reasons previously discussed, the method of the present invention makes possible the thorough and uniform processing of the threads. Such uniformity is, of course, reflected in the high .quality of the staple fiber produced according to the present invention. The staple fiber produced according to the invention may therefore be in the completely finished condition, even bleached if desired, of a highly uniform character and in a form advantageously usable.

Moreover, since the necessary processing treat; ments. may all be applied to the threads before they are cut and because of the above-mentioned parallelism of the filaments, the fibers of the staple fiber of the present invention are not tangled or snarled. Consequently, they requireno unusual opening, carding, gilling, combing or like treatments prior to spinning into yarn. Broken fibers which invariably result from such drastic treatment and which add considerable difficulties in the operation of spinning the fibers into yarn are therefore not present in slivers formed of the staple fiber of the present invention.

The initial uniformity of the length of the staple fiber of the present invention is made possible because the bundle of filaments may be cut, as above indicated, while it is in the form of a moist, fiat ribbon in which the filaments are coherent and in which no tendency of the filaments to slide during the cutting operation is .present. For these reasons the fibers may be cut to the exact desired length and all fibers may be of highly uniform length. As previously indicated, such uniformity in the length of the fibers is difficult, if not impossible, of attainment in the methods of manufacturing staple fiber heretofore employed.

Because of the highly crinkled condition of the fibers of the staple fiber produced according to the present invention, the coherence or clinging power of the fibers is considerably increased. Therefore, because of the extreme uniformity of 7 length of the fibers, the initial parallelism thereof; and the untangled condition thereof, the staple fiber of the present invention may be spun into yarn with much more facility than is possible with the staple fiber heretofore commercially produced. Moreover, for these reasons and particularly because of the highly crinkled condition of the fibers, spun yarn, produced from or having incorporated therein the staple fiber of the present invention is of extraordinarly high strength. Therefore, because of the extreme uniformity and high quality of the staple fiber of the present invention, it is possible to produce staple fiber spun yarn of a better qualitythan has heretofore been commercially available.

The chip form in which the staple fiber of the present invention may be produced possesses numerous great and novel advantages not found in the staple fiberheretofore commercially produced. Because of the compact, integral form the of the chips, caused by the coherence of the fibers, no appreciable fuzzing or spreading of the fibers is present. This condition persists and little disintegration of the chips occurs even though the chips are subjected to handling, such as that occurring in baling the chips, shipping them, and unpacking them. Consequently, even after being so iandled, the chips retain their individual form, whereas the staple fiber commercially produced according to the methods heretofore employed is invariably in the form of a loose, more or less tangled mass-when it is about to be spun into yarn.

Since the staple fiber of the present invention is clean, no dirt or impurities being present, and because of the compact, integral nature'of the chips, the parallelism of the fibers of the chips and the fact that the fibers are not fluifed or tangled, it has been found that it is not necessary to subject the chips to a separate opening operation, as is generally necessary in the case of staple fiber otherwise produced. Instead, the staple fiber chips of the present invention may, if desired, be fed directly to the carding machine. Even with only a light carding operation, the chips are opened and a highly satisfactory sliver is formed.

combing, if at all necessary, likewise need be only slight, since because of the untangled, parallel disposition of the fibers in the chips, little' or no damage occurs to the fibers during the preceding operations. Because of the light treatment required to prepare the staple fiber of the present invention for twisting into yarn, the

amount of waste occurring during such treatbecause of the crinkled nature of the fibers, which gives them considerable coherence, and because of the extremely uniform length of the fibers,

whereby difficulties due to too short or too long fibers are obviated. The cost of forming spunyarn of the above-indicated superior quality from the staple fiber of the present invention is therefore low, since large savings in time and labor result because of the small amount of preparatory treatment required prior to twisting, because'of the low, almost negligibIe,-loss of stock during such preparatory treatment as is applied, and because of the ease with which the staple fiber of the present invention may be twisted into yarn.

If short length staple fiber is produced, such as may be desirable for the cotton system of spinning, it may be desirable to subject the chips to a slight opening operation, since yarn manufacturers producing this type of yarn sometimes require it in this form. However, because of the uniformity of the product obtained according to the present invention, the uniformity of length of the fibers, and the crinkled nature of the fibers, such staple fiber produced according to the present invention may also be'readily spun into yarn with aminimum of difliculty, and therefore also possesses marked advantages over that hereto fore commercially produced.

to those above discussed will be apparent to those skilled in the art. a

It is apparent that various modifications may be made in the described methods and apparatus of the invention without departing from the spirit of the invention. Thus, the thread-storage devices may, if desired, be of other types than those described. The devices may be disposed in other arrangements than that illustrated and more or'fewer series of thread-storage devices than the illustrated number may be' provided. Furthermore, it is obvious that a separate severing device may be provided for the threads processed on each side oi the machine, if desired. Such modifications are but illustrative of those which may be made within the scope of the present invention.

It is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty reside in the invention. i

What is claimed is:

1. In the manufacture of staple fiber by a continuous wet spinning process,- the steps comprising continuously forming a bundleof filaments;

imposing on said bundle of filaments at one or more points in its path of travel the form of an advancing helix characterized by a large number of turns; continuously processing said bundle of filaments while in such helical form; imparting a fiat, ribbon-like form to said bundle of filaments; cutting said bundleoi filaments while wet into chips of staple length; and drying said chips while still in the flat, ribbon-like form characterizing said bundle of filaments at the time the cutting operation is performed.

2. In the manufacture of staple fiber by a continuous wet spinning process, the steps comprising continuously forming a' bundle of filaments; imposing'on said bundle of filaments at one or more points -in its path of travel the form of an advancing helix characterized by a large number of turns; continuously processing said bundle of filaments while in such helical form; compressing said bundle of filaments into compact form, so that the surface tension of the liquid remaining in said bundle causes the filaments to cohere; cutting said bundle of filaments while wet into chips of staple length; and drying said chips in the compact form characterizing said bundle of filaments at the time the cutting operation is performed.

3. In the manufacture of staple fiber by a continuous wet spinning process, the steps comprising continuously forming aplurality of bundles of filaments; continuously subjecting each of said bundles to one or more liquid proc-- essing treatments; combining a plurality of said bundles into a single large bundle; compressing said large bundle of filaments into .compact form, soi that the surface tension of the liquid remaining in said bundle causes the filaments to cohere; cutting said large bundle of filaments while wet into chips of staple length; and drying said chips inthe compact form characterizing said large bundle of filaments at the time .the cutting operation is performed. v

4. In the manufacture of staple fiber by a continuous wet spinning process, the steps comprising continuously forming a plurality of threads; combining said threads into a plurality of bundles, each of said bundles comprising several threads; continuously subjecting each or said surface tension of the liquid remaining in said bundle causes the filaments to cohere; cutting said large bundle while moist into chips of staple length; and drying said chips in the compact form characterizing said large bundle of filaments at the time the cutting operation is performed.

5. In the manufacture of staple fiber by a continuous wet spinning process, the steps comprising continuously forming a plurality ofthreads; imposing on each of said threads at one or more points in its path of travel the form of an advancing helix characterized by a large number of turns; continuously processing each of said threads while insuch helical form; combining a plurality of said threads into a bundle; imparting a fiat, ribbon-like form tosaid bundle; cutting said bundle while moist into chips of staple length; and drying said chips while stillin the fiat, ribbon-like form characterizing said bundle at the time the cutting operation is performed.

6. In the manufacture of staple fiber by a continuous wet spinning process, the steps comprising continuously forming a plurality of small and drying said chips while still in the fiat, ribbon-like form characterizing saidbundle at the time the cutting operation is performed.

'7. Apparatus for manufacturing filament aggregates characterized by the'presence of substantially parallel fibers of staple length comprising a horizontally extending series of unitary thread-advancing reels disposed with the discharge ends of all reels facing in one and the same direction, each of said reels positively advancing the thread toward the discharge end thereof in a large number of substantially helical turns; means at one end of said series or reels for forming a thread which travels in turn to each of the reels of said series; means intermediate the ends of said'series of reels for subjecting the thread to processing treatment; means at the opposite end of said series of reels for reducin to fibers of staple length thefilame'nts going to make up the processed thread; and, disposed in juxtaposition to said last-mentioned means, a drying chamber adapted to receive the product immediately after its discharge from said lastmentioned means without substantial impairment of the parallelism of the fibers.

8. Apparatus as in claim 7 embodying a plurality of superposed horizontally extending series of thread-advancing reels and, common to said series, a single device for reducing the threads to fibers of staple length.

9. Apparatus as in claim 7 embodying a plurality of superposed horizontally extending series of thread-advancing-reels and, common to said series, a single chamber for drying the product.

HAYDEN B. KLINE. LAVERN J. JORDAN. 

